Externally configurable worksite power distribution box

ABSTRACT

Systems and methods for configuring, with an external device, a power distribution box having priority disconnects. The power distribution box includes a housing portion and a base portion elevating the housing portion. The power distribution box receives power from an external power source and distributes the power to a plurality of alternating current (AC) output receptacles. The power distribution box further includes an antenna and a power disconnect controller coupled to the antenna to communicate with and be configured by an external device, such as a smart phone, tablet, or laptop computer. Using the external device, a user can configure the priority level and mode of the AC output receptacles. In the case of high current, the power distribution box will disconnect receptacles in accordance with the priority level and mode configuration provided by the external device.

RELATED APPLICATIONS

This application claims the priority benefit of U.S. ProvisionalApplication No. 62/249,393, filed on Nov. 2, 2015, the entire content ofwhich is hereby incorporated by reference.

FIELD OF THE INVENTION

The invention relates to systems and methods for distributing power at aworksite.

BACKGROUND

Temporary power systems distribute power at worksites, such asconstruction projects, where permanent power is not available. Forinstance, in constructing a building, an on-site generator may generatepower for use by construction workers for powering various tools anditems, such as power drills, saws, radios, computers, lighting, etc.Alternatively, a temporary connection to a power utility grid may beused.

SUMMARY

In one embodiment, a method for configuring a power distribution box isprovided. The method includes establishing, by the power distributionbox, a wireless communication link with an external setting device andreceiving, over the wireless communication link from the externalsetting device, disconnect configuration data for a plurality of outletcircuits of the power distribution box. The method further includesconfiguring the power distribution box by setting a priority level foreach of the plurality of outlet circuits in accordance with thedisconnect configuration data. The method also includes receiving, at apower input of the power distribution box, alternating current (AC)power from an external power source and distributing the AC powerreceived from the external power source to the plurality of outletcircuits in accordance with the disconnect configuration data.

In another embodiment, another method for configuring a powerdistribution box is provided. The method includes establishing, by anexternal setting device, a wireless communication link with the powerdistribution box. On a screen of the external setting device, aconfiguration screen for the power distribution box is provided. Themethod further includes receiving user input specifying new disconnectconfiguration data. The new disconnect configuration data includes apriority level for each of a plurality of outlet circuits of the powerdistribution box. The new disconnect configuration data is transmittedto the power distribution box to configure the power distribution box.

In another embodiment, a power distribution box operable to beconfigured is provided. The power distribution box includes a housingportion and a base portion elevating the housing portion above a surfaceon which the power distribution box is placed. The power distributionbox also includes a power source input operable to receive power from anexternal power source and a plurality of outlet circuits electricallycoupled to the power source input. Additionally, the power distributionbox includes an antenna and a power disconnect controller. The powerdisconnect controller is coupled to the antenna and is configured toestablish a wireless communication link with an external setting device.The power disconnect controller is also configured to receive, over thewireless communication link, disconnect configuration data. The powerdisconnect controller has priority levels assigned to the plurality ofoutlet circuits as specified by the disconnect configuration datareceived from the external setting device.

Embodiments of the invention involve configuring a power distributionbox having priority disconnects and used to distribute temporary power.Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a temporary power distribution system according toembodiments of the invention.

FIG. 2 illustrates a diagram of a power box having a priority disconnectmodule and antenna.

FIG. 3 illustrates a power box in communication with an external deviceaccording to embodiments of the invention.

FIGS. 4A and 4B illustrates power box current graphs.

FIG. 5 illustrates a partial circuit diagram of a power box inaccordance with embodiments of the invention.

FIG. 6 illustrates a flow chart for implementing a priority disconnecton a power box in accordance with embodiments of the invention.

FIG. 7 illustrates a flow chart for configuring a power box using anexternal device in accordance with embodiments of the invention.

FIG. 8 illustrates another flow chart for configuring a power box usingan external device in accordance with embodiments of the invention.

FIGS. 9-10 illustrate graphical user interfaces implemented on anexternal device and used to configure a power box in accordance withembodiments of the invention.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting.

It should also be noted that a plurality of hardware and software baseddevices, as well as a plurality of different structural components maybe used to implement the invention. In addition, it should be understoodthat embodiments of the invention may include hardware, software, andelectronic components or modules that, for purposes of discussion, maybe illustrated and described as if the majority of the components wereimplemented solely in hardware. However, one of ordinary skill in theart, and based on a reading of this detailed description, wouldrecognize that, in at least one embodiment, the electronic based aspectsof the invention may be implemented in software (e.g., stored onnon-transitory computer-readable medium) executable by one or moreprocessors. As such, it should be noted that a plurality of hardware andsoftware based devices, as well as a plurality of different structuralcomponents may be utilized to implement the invention. Furthermore, andas described in subsequent paragraphs, the specific mechanicalconfigurations illustrated in the drawings are intended to exemplifyembodiments of the invention and that other alternative mechanicalconfigurations are possible. For example, “controllers” described in thespecification can include standard processing components, such as one ormore processors, one or more computer-readable medium modules, one ormore input/output interfaces, and various connections (e.g., a systembus) connecting the components.

FIG. 1 illustrates an exemplary temporary power distribution system 100.The system 100 includes a power source, such as one or both of a utilitygrid power source 102 a and a mobile generator power source 102 b(generically referred to as the power source 102). One of the utilitygrid power source 102 a and the mobile generator 102 b is generallyoperating, while the other is either not present in the system 100 or onstandby. In some instances, the mobile generator 102 b acts as a backuppower source in case of a power outage of the utility grid power source102 a.

The utility grid power source 102 a is coupled to a local transformersubstation 106 and provides a 50 Ampere (A), 440 volt, alternatingcurrent (VAC) power supply. The substation 106 transforms the inputpower to one or more 50 A, 120 VAC power supply lines, one of which isprovided to the power distribution box (“power box”) 110 a. In someinstances, the substation 106 is considered part of the utility gridpower source 102 a. The mobile generator 102 b is also operable tooutput a 50 A, 120 VAC output to the power box 110 a. The power box 110a receives the output of the power source 102 at an input receptacle,which is electrically coupled to an output receptacle of a power box 110a. A daisy chain cable 112 is coupled to the output receptacle of thepower box 110 a and to an input receptacle of a power box 110 b. A powerbox 110 c is similarly coupled by a daisy chain cable 112 to the powerbox 110 b. Thus, the output of the power source 102 is shared among eachof the power boxes 110 a-c, which are generically referred to as thepower boxes 110. In some instances, the substation 106 and/or mobilegenerator 102 b output multiple 50 A, 120 VAC outputs, each connected toa separate power box 110 or string of power boxes 110.

The power boxes 110 distribute the received power to various outlets oneach respective power box 110. For example, each of the power boxes 110illustrated in FIG. 1 include four 120 VAC outlets and two 5 volt,direct current (VDC) USB® type outlets, each powered by the powerreceived at the input receptacle from the power source 102. At aworksite, various tools and other electronic devices may be coupled tothe outlets of the power boxes 110. For instance, the power boxes 110are coupled to one or more of an electric drill/driver 114 (120 VAC), aworksite radio 115 (120 VAC), a smart phone 116 (5 VDC); and a circularsaw 117 (120 VAC).

Although not shown in detail, one or more of the output receptacles mayinclude cables and receptacles with twist-to-lock/unlock mechanisms forsecuring cables to the power boxes 110. Additionally, the outputreceptacles may be recessed and include water-tight, hinged covers toprevent water ingress near the conductive elements. Alternativeembodiments of the invention include different power, current, andvoltage levels, different current thresholds, different numbers ofoutput receptacles, and different types of output receptacles.

The particular voltage levels of power lines described in thisapplication are exemplary and approximate. For instance, the substation106 may provide a single 240 VAC supply line to the power boxes 110, ortwo 120 VAC supplies lines that are combined to form a 240 VAC supplyline. In such instances, the power boxes 110 may also include one ormore 240 VAC outlets in addition to the 120 VAC outlets and 5 VDC USB®outlets. Additionally, the particular values are approximate and mayvary in practice. For instance, the 120 VAC line may be nearer to about110 VAC, and the 240 VAC supply line may be nearer to about 220 VAC.Furthermore, the power boxes 110 are illustrated and described herein ashaving common U.S.-style outlets and voltage levels. However, the powerboxes 110 may be adapted for use with other outlet types and voltagelevels, such as those common in Japan, Great Britain, Russia, Germany,etc.

The power boxes 110 further include an antenna 126 positioned on ahousing 127. The housing 127 includes a base 128 to elevate the powerboxes 110 above the ground, e.g., by 2 to 18 inches. The housing 127 mayhave a ruggedized construction including plastic and/or metal towithstand impacts, dropping, harsh weather, moisture, and other commonwear and tear that occurs on a worksite. The base 128 includes legs 129.The base 128, housing 127, and legs 129 may be integral components orcomponents that are secured to one another, e.g., via fasteners,welding, adhesive, etc. The elevation provided by the base 128 maintainsthe power boxes 110 out of water, dirt, contaminants, and hazardousmaterials that may be found on the ground of a worksite and that maypose issues to the power boxes 110 and safety risks.

FIG. 2 illustrates the power box 110 in greater detail. As describedabove, the power box 110 includes an input receptacle 130 for receivinga 50 A, 120 VAC power supply line 131 from the power source 102. Theinput receptacle 130 is electrically coupled to the output receptacle132 via power lines 134, which may then be coupled to another power box110 via a daisy chain cable 112. The power lines 134 include a hot,neutral, and ground line, which are coupled to a main circuit breaker136. The main breaker 136 is a “slow-blow” breaker that selectivelyopens when the current level drawn downstream of the main breaker 136exceeds a predetermined threshold, such as 20 A or 25 A, for a certainamount of time, such as 100 milliseconds (ms). When opened, the mainbreaker 136 severs the electrical connections between the power lines134 and the sub-breakers 138. The main breaker 136 may be manually resetby a user to re-connect the power lines 134 to the downstreamcomponents, such as by flipping a toggle switch.

An output side of the main breaker 136 is coupled to severalsub-breakers 138 a-e, which are generically referred to as thesub-breakers 138. The sub-breakers 138 are similar to the main breaker136 in function and may have the same predetermined threshold as themain breaker 136, or a predetermined threshold that is lower than themain breaker 136, such as 15 A or 20 A. The power box 110 furtherincludes one or more breaker sensors 139 to detect the state of each ofthe main breaker 136 and the sub-breakers 138 a-e, which may be eitherin a closed state or an open/tripped state. Each of the sub-breakers 138a-d is coupled to a respective outlet circuit 140 a-d, each of whichincludes one or more 120 VAC output receptacles 142. Each outputreceptacle 142 may be a ground fault circuit interrupter (GFCI) circuitfor further safety, and may include a test and reset button (not shown).Sub-breaker 138 e is coupled to a rectifier 144 for converting the 120VAC to 5 VDC for providing to two direct current (DC) outlets 146, suchas USB® outlets.

The power box 110 further includes a priority disconnect controller (“PDcontroller”) 150. The PD controller 150 is coupled to the breakersensors 139, which provide an indication of the states of the mainbreaker 136 and the sub-breakers 138 a-e to the PD controller 150. ThePD controller 150 is further coupled to a current sensor 152 thatmonitors the current drawn by the sum of the components of the power box110 downstream from the main breaker 136, including the current drawnvia each of the outlet circuits 140 a-d and DC outlets 146. Although notshown, the PD controller 150 and other non-illustrated circuits of thepower box 110 are also powered by the power lines 134 via the mainbreaker 136.

The PD controller 150 is further coupled to current sensors 153 a, 153b, 153 c, and 153 d and to disconnect switches 154 a, 154 b, 154 c, and154 d. The PD controller 150 is operable to monitor the current drawn onthe circuits of each of the sub-breakers 138 a-d. For instance, thecurrent sensor 153 a indicates the current drawn by the two receptacles142 of the outlet circuit 140 a. In some instances, a further currentsensor and disconnect switch are provided for the DC outlet circuit ofthe sub-breaker 138 e.

The PD controller 150 is also operable to control disconnect switches154 a-d to selectively open and close. When a disconnect switch (e.g.,switch 154 a) is opened, the associated one of the outlet circuits 140a-d becomes an open circuit that no longer conducts electricity to powera device plugged into one of the receptacles 142 of the associated oneof the outlet circuits 140 a-d.

The PD controller 150 selectively opens and closes the disconnectswitches 154 a-d dependent on a disconnect configuration of the PDcontroller 150 and outputs of the current sensors 153 a-d received bythe PD controller 150. The disconnect configuration may define variouscurrent thresholds, a mode for each outlet circuit, and a priority levelfor each outlet circuit. For instance, the PD controller 150 offersindividual circuit protection for each of the outlet circuits 140 a-dbased on an individual circuit current threshold, which is generally setto trigger before the associated breaker 138 a-d. For example, assumingthe sub-breaker 138 a opens when current exceeds 15 A for 100 ms, the PDcontroller 150 may selectively open the outlet circuit 140 a when itexceeds an individual circuit current threshold of 14.5 A for 75 ms or15 A for 50 ms.

As noted, the disconnect configuration of the PD controller 150 maydefine various current thresholds, a mode for each outlet circuit 140,and a priority level for each outlet circuit 140. With reference to FIG.3, the disconnect configuration of the PD controller 150 may be definedby disconnect configuration data 160 wirelessly provided by an externaldevice 162, also referred to as an external setting device 162. Forinstance, FIG. 3 illustrates the PD controller 150 including a memory164, a processor 166, sensor input interface 168, control outputinterface 170, a wireless communication module 172, and a communicationbus 173 allowing communication therebetween. The sensor input interface168 includes a circuit interface (e.g., conductive pins) for connectingto and receiving data signals from the current sensors 152 and 153 a-d.The sensor input interface 168 conditions and provides the received datasignals to the processor 166. The control output interface 170 includesa circuit interface (e.g., conductive pins) for connecting to thedisconnect switches 154 a-d. The control output interface 170 conditionsand provides control signals received from the processor 166 to thedisconnect switches 154 a-d.

The memory 164 stores data, such as the disconnect configuration data160, and instructions for use by the processor 166 to carry out thefunctionality of the PD controller 150 described herein. For instance,the processor 166 may read software instructions from the memory 164causing the processor 166 to compare current measurements obtained viathe sensor input interface 168 to current thresholds of the disconnectconfiguration data 160, and to generate control signals that areprovided to the disconnect switches 154 a-d via the control outputinterface 170 according to the modes and priority levels of the outletcircuits 140 defined by the disconnect configuration data 160.

The wireless communication module 172 is coupled to the antenna 126 andenables the PD controller 150 to communicate with the external device162. For instance, the wireless communication module 172 includescircuitry, such as buffers and data drivers, to enable communication viathe antenna 126 with the external device 162 according to one or morecommunication protocols. The external device 162 is, for instance, asmart phone, tablet computer, laptop computer, desktop computer,personal digital assistant (PDA), or similar computing device.

The external device 162 includes a device antenna 174, a device wirelesscommunication module 176, a device memory 178, a device processor 180,and a device user interface 182. The device wireless communicationmodule 176, like the wireless communication module 172, includescircuitry, such as buffers and data drivers, to enable communication viathe device antenna 174 with the power box 110. The wirelesscommunication module 172 and antenna 126 selectively form abidirectional, wireless communication link 184 with the device wirelesscommunication module 176 and device antenna 174. The wirelesscommunication module 172, the antenna 126, the device wirelesscommunication module 176, and the device antenna 174 may communicateaccording to one or more communication protocols, such as the Bluetooth®protocol, the Wi-Fi® protocol, a near-field communication (NFC)protocol, or other protocols. In some embodiments, the wirelesscommunication link 184 is a direct communication link thatcommunicatively connects the antenna 126 and the device antenna 174without intervening network devices, such as a router.

The device user interface 182 provides human perceptible outputs andreceives human entered inputs allowing a user to interact with theexternal device 162. For instance, the device user interface 182 mayinclude one or more of a touch screen display, hard key buttons (e.g., akey pad), a speaker, microphone, tactile feedback generators, or othercomponents. The device memory 178 stores data and instructions for useby the device processor 180 to carry out the functionality of theexternal device 162 described herein. For instance, the device processor180 may read software instructions from the device memory 178 causingthe external device 162 to form the wireless communication link 184, toreceive the disconnect configuration data 160 from the PD controller 150over the wireless communication link 184, receive modifications for thedisconnect configuration data 160 entered by the user via the deviceuser interface 182, and send back the disconnect configuration data 160,as modified by the user, to the PD controller 150 over the wirelesscommunication link 184.

The disconnect configuration data 160 defines a priority level for eachoutlet circuit 140 a-d. The PD controller 150 uses the priority levelsto determine whether to open particular disconnect switches 154 a-d. Asan example, the disconnect configuration data 160 provides that theoutlet circuit 140 a has the highest priority level (priority 1), outletcircuit 140 b has a lower priority level (priority 2), outlet circuit140 c has a lower priority level (priority 3), and outlet circuit 140 dhas the lowest priority level (priority 4). The PD controller 150monitors the sum current drawn by the sum of the outlet circuits 140using either the sum of the outputs of the current sensors 153 a-d, orby using the current sensor 152. The PD controller 150 also has apredetermined priority disconnect threshold that is set to triggerbefore the main breaker 136 opens. For instance, FIG. 4A illustrates agraph of sum current over time, a main breaker threshold 156 of the mainbreaker 136, and the priority disconnect threshold 158. The main breakerthreshold 156 is set at 20 A, while the priority disconnect threshold158 is set at 19 A.

As shown in FIG. 4A, when the sum current first exceeds the prioritydisconnect threshold 158, the PD controller 150 determines whichdisconnect switch 154 has the lowest priority and opens that switch(e.g., disconnect switch 154 d). In response, the sum current then dropsbelow the priority disconnect threshold 158. Later, the sum currentexceeds the priority disconnect threshold 158 again. The PD controller150 determines which disconnect switch 154 of the remaining closedswitches has the lowest priority (i.e., disconnect switch 154 c). As thesum current remains above the priority disconnect threshold afteropening disconnect switch 154 c, the PD controller 150 determines andopens the remaining disconnect switch 154 having the lowest priority(i.e., disconnect switch 154 b). The sum current then drops below thepriority disconnect threshold, with only the disconnect switch 154 aremaining closed.

The PD controller 150 automatically disconnects outlet circuits 140based on the set priority levels to keep the main breaker 136 fromopening. Accordingly, a high priority tool or device (e.g., worksitelighting) coupled to a high priority outlet circuit 140, such as theoutlet circuit 140 a, remains powered. In contrast, the main breaker ofa power box without the priority disconnect scheme or of the power box110 having all outlet circuits 140 set to always-on mode (describedbelow) would likely have opened, severing power to all devices connectedto the power box 110 (see FIG. 4B).

The outlet circuits 140 can be assigned fewer or greater priority levelsthan four levels, as described above. For instance, the priority levelsmay include merely a low and high priority selection; a low, medium, andhigh priority level; or the same number of priority levels as outletcircuits 140.

As noted, the disconnect configuration data 160 may also define a modefor each outlet circuit 140. The mode may be either a prioritydisconnect mode or an always-on mode. The always-on mode is a mode inwhich the priority disconnect feature is disabled for the associatedoutlet circuit 140, and the priority disconnect mode is a mode in whichthe priority disconnect feature is enabled for an associated outletcircuit 140. As shown in FIG. 5, an always-on switch 186 provides abypass conducting path that bypasses an associated disconnect switch 154a. FIG. 5 illustrates one of the outlet circuits 140 (the outlet circuit140 a) and associated circuitry for illustration purposes. However, thearrangement is similarly applicable to the other outlet circuits 140present on the power box 110 to individually and selectively place theparticular outlet circuits 140 in the always-on mode, as desired. Withthe bypass path, current is not interrupted to the outlet circuit 140that is in the always-on mode even though the PD controller 150 maycontrol the associated disconnect switch 154 to open.

In another embodiment, the always-on switch 186 is not included for eachoutlet circuit 140. Rather, when the always-on mode is selected for aparticular outlet circuit 140, as defined by the disconnectconfiguration data 160, the PD controller 150 does not control theassociated disconnect switch 154 a-d to open. In the always-on mode, thebreakers 136, 138 still provide circuit protection in the event of anover-current situation for an associated outlet circuit 140.

In some embodiments, the disconnect configuration data 160 defines theoutlet circuits 140 as being in either an always-on mode or a lowpriority mode. When the priority disconnect threshold is exceeded, thePD controller 150 determines the current level of each of the lowpriority outlet circuits 140 and opens the disconnect switch associatedwith the highest current drawing outlet circuit 140.

Additionally, in some instances, two outlet circuits 140 (e.g., 140 aand 140 b) may have the same priority (e.g., priority 1). If two outletcircuits 140 have the same priority, the PD controller 150 may open bothassociated disconnect switches 154 when the PD controller 150 determinesthat (1) the priority disconnect threshold is exceeded and (2) thepriority level of the two outlet circuits 140 are the lowest priority ofthe remaining outlet circuits 140 having closed disconnect switches. Insome instances, if two outlet circuits 140 have the same priority andthe priority disconnect threshold is exceeded, the PD controller 150 maydetermine which of the outlet circuits 140 has a larger current draw andopen the disconnect switch 154 associated with that outlet circuit 140.

FIG. 6 illustrates a method 200 of implementing a priority disconnectscheme on the power box 110. In step 202, the external device 162configures the power box 110. The configuration includes setting apriority level of each of the outlet circuits 140 and setting a mode ofeach of the outlet circuits 140 to be either in an always-on mode or apriority disconnect mode. In some instances, the outlet circuits 140 mayhave the mode setting feature or the priority setting feature, but notboth. In such instances, step 202 includes configuring the feature thatis present. Step 202 is described in further detail below with referenceto FIGS. 7 and 8.

In step 204, the power box 110 distributes power after being coupled tothe power source 102 and after having one or more devices coupled to thereceptacles 142. One or both of steps 202 and 204 may be performed in adifferent order, simultaneously, and/or multiple times before reachingstep 206.

In step 206, the PD controller 150 detects various current levels of thepower box 110. For instance, the processor 166 monitors the outputs ofthe current sensors 152 and 153 a-d. In step 208, the PD controller 150determines whether an individual circuit current threshold of one of theoutlet circuits 140 has been exceeded based on outputs of the currentsensors 153 a-d. If one or more individual circuit current thresholdshave been exceeded, the PD controller 150 opens the disconnect switches154 a-d associated with the outlet circuit(s) 140 a, 140 b, 140 c,and/or 140 d having excessive current (step 210). If no individualcircuit current thresholds have been exceeded, the PD controllerdetermines whether the sum current, e.g., as detected by current sensor152, has exceeded the priority disconnect threshold (step 212). If not,the PD controller 150 loops back to step 206 to again detect the currentlevels of the power box 110.

If the priority disconnect threshold has been exceeded, the PDcontroller 150 determines in step 214 which of the disconnect switches154 a-d to open based on the priorities and modes set in step 202. Forinstance, in step 214, the PD controller 150 determines which of theoutlet circuits 140 has the lowest priority. Then, in step 216, the PDcontroller 150 controls the disconnect switches 154 a-d associated withthe determined, lowest priority outlet circuits to open. As describedwith respect to FIGS. 4A-B, the disconnect switch(es) 154 are opened toreduce the current drawn by the power box 110 to be below the prioritydisconnect threshold 158. If the opened disconnect switches 154 succeedin reducing the sum current, the power box 110 will continue todistribute power on the outlet circuits 140 that remain active withclosed disconnect switches 154. The sum current may remain above thepriority disconnect threshold even with an opened disconnect switch if,for instance, the particular outlet circuit 140 was in an always-onmode, or if the other outlet circuits 140 have high current levels.Accordingly, the PD controller 150 cycles back to step 206 to proceedback through steps of the method 200 to determine whether to openfurther disconnect switches. In some instances, if a user alterspriority or mode settings during steps 204-216, the method 200 returnsto step 202.

In some embodiments, in step 214, the PD controller 150 may alsodetermine whether the outlet circuits 140 are in an always-on mode or apriority disconnect mode based on the disconnect configuration data 160.If one or more outlet circuit 140(s) are in an always-on mode, the PDcontroller 150 excludes those outlet circuit 140(s) from beingconsidered as having the lowest priority level.

In some embodiments, the PD controller 150 determines which of theoutlet circuits 140 having the lowest priority is drawing the mostcurrent in step 214. Then, in step 216, the PD controller 150 opens thathigh current outlet circuit 140.

The PD controller 150 may leave an opened disconnect switch of one ofthe outlet circuits 140 open until a user reset or for a predeterminedamount of time (e.g., five seconds). For instance, FIG. 5 illustrates aportion of the power box 110 of FIG. 2 wherein the PD controller 150includes a reset button 250 that indicates to the PD controller 150 toclose the switch 154 a. Alternatively, depressing the reset button 250may manually close an associated disconnect switch or the externaldevice 162 may send a reset signal, in response to user input, to closean opened disconnect switch.

The disconnect switches 154 a-d may each be associated with indicatorlights. The indicator lights may be, for example, light emitting diodesthat are selectively illuminated to indicate the status of theassociated disconnect switch 154 a-d. For example, with reference toFIG. 5, if the disconnect switch 154 a is closed, the associatedindicator light 252 is activated to indicate to a user that thedisconnect switch 154 a is conducting and that the outlet circuit 140 ais active. In other embodiments, the indicator lights are selectivelycontrolled, e.g., by the PD controller 150, to illuminate when anassociated disconnect switch 154 a-d has been opened. In someembodiments, the indicator lights (e.g., indicator light 252) isselectively controlled, e.g., by the PD controller 150, to indicate whencurrent of one of the outlet circuits 140 is approaching its individualcircuit current threshold based on outputs of the current sensors 153a-d. For example, the PD controller 150 may control the associatedindicator light 252 associated with the particular outlet circuit 140 toflash or be illuminated in a warning color (e.g., yellow). Accordingly,the PD controller 150 is operable to control the indicator light 252 ofeach outlet circuit 140 to change between multiple operating states toindicate whether the outlet circuit 140 is conducting, whether theoutlet circuit 140 is approaching its individual circuit currentthreshold, and whether the associated disconnect switch 154 a-d has beenopened.

In some embodiments, additionally or alternatively, the PD controller150 controls the indicator light 252 (or both the indicator light 252and indicator lights associated with the other outlet circuits 140) toindicate when the sum current of the outlet circuits 140 is approachingthe priority disconnect threshold 158 based on outputs of the currentsensors 153 a-d. For example, the PD controller 150 may control one ormore of the indicator lights to flash or be illuminated in a warningcolor (e.g., yellow). To determine whether current is approaching athreshold (e.g., the individual circuit current threshold or thepriority disconnect threshold 158), the PD controller 150 may compareoutput of the current sensors 153 a-d to a threshold that is lower(e.g., by 5%) than the associated threshold.

In some embodiments, the PD controller 150 provides a notification tothe external device 162 upon controlling one of the disconnect switches154 a-d to open. For example, the notification may include an identityof the power box having the opened one or more disconnect switches 154a-d and an identity of each of the disconnect switches 154 a-d that areopened, which are then displayed on and/or audibly conveyed by theexternal device 162. Such notifications may be provided, for example,upon opening one or more of the disconnect switches 154 a-d in steps 216and 210 of method 200.

In some embodiments, the PD controller 150 may be coupled to breakersensors (not shown) for each of the main breaker 136 and sub-breakers138 a-d operable to indicate to the PD controller 150 the state of theassociated breaker (e.g., closed or open/tripped). The PD controller 150detects when the main breaker 136 trips and when one or more of thesub-breakers 138 a-e trips, and provides a notification to the externaldevice 162 upon such detection. For example, the notification mayinclude an identity of the power box having the tripped breaker and anidentity of the detected breaker that tripped, which are then displayedon and/or audibly conveyed by the external device 162.

FIG. 7 illustrates a method 300 of configuring the power box 110 usingthe external device 162. The method 300 may be implemented to effectstep 202 of FIG. 6. In step 302, the power box 110 advertises orperiodically broadcasts an advertisement message, which is received bythe external device 162 when in range. The advertisement messageincludes identification information regarding the power box 110 identity(e.g., serial number, a user assigned identifier or another uniqueidentifier).

In step 304, the power box 110 establishes a communication link (e.g.,the wireless communication link 184) with the external device 162.Establishing the communication link may include an exchange of messages(e.g., handshake) including identifying information for the power box110 and the external device 162, communication characteristics (e.g.,timing and/or frequency information for communications), and other data.

After establishing the communication link, the power box 110 sends thedisconnect configuration data 160 presently stored in the memory 164(current disconnect configuration data) to the external device 162 (step306). In step 308, the power box 110 receives new disconnectconfiguration data from the external device 162. In step 310, toconfigure the power box 110, the power box 110 stores the receiveddisconnect configuration data in the memory 164 as the disconnectconfiguration data 160, overwriting the previous configuration data.Accordingly, through step 310, the PD controller 150 has prioritylevels, modes, or both (e.g., in the memory 164) assigned to the outletcircuits 140, as specified by the received disconnect configurationdata. In step 312, the power box operates according to the disconnectconfiguration data 160 newly received and stored. For instance, for step312, the power box 110 may implement steps 204-216 as described abovewith respect to FIG. 6.

FIG. 8 illustrates a method 350 of configuring the power box 110 usingthe external device 162. The method 350 may also be implemented toeffect step 202 of FIG. 6. In step 352, the external device 162 receivesan advertisement message broadcast by the power box 110. Also in step352, the external device 162 may receive additional advertisementmessages from other power boxes 110 or from other power tool devices(e.g., an electric drill/driver 114, circular saw 117, or power toolbattery packs). The advertisement messages are received by the devicewireless communication module 176 via the device antenna 174. Theexternal device 162 determines one or more of the specific make, model,and serial number of devices that transmitted the advertisementmessages, including the power box 110. In step 354, the external device162 displays a list of devices from which advertisement messages werereceived, including the power box 110. For instance, the list of devicesis generated by the device processor 180 and shown on a touch screen ofthe device user interface 182. In step 356, the external device 162receives a user selection of the power box 110 from the list of devicesvia the device user interface 182.

In step 358, in response to receiving the user's selection, the externaldevice 162 establishes a communication link with the power box 110, asdescribed with respect to step 304 of FIG. 7. In step 360, the externaldevice 162 receives the current disconnect configuration data from thepower box 110, transmitted by the power box 110 as described withrespect to step 306.

In response, in step 362, the external device 162 generates aconfiguration screen for the power box 110, which is displayed on thedevice user interface 182. The configuration screen illustrates outletcircuits 140 of the power box 110 that are configurable and one or moreof the current priority levels of the outlet circuits 140, the mode ofthe outlet circuits 140, and current thresholds of the power box 110.Via the device user interface 182, in step 364, the external device 162receives user input to adjust the settings of the disconnectconfiguration data on the configuration screen and, thereby, generatenew disconnect configuration data. For instance, the external device 162receives user input to modify one or more of a priority level for eachoutlet circuit 140, a mode (e.g., always-on or priority disconnect) foreach outlet circuit 140, and a current threshold for each outlet circuit140. Thus, a user may modify settings for each outlet circuit 140, oropt to modify only those settings desired, such as the priority level oftwo outlet circuits 140 and the mode of another outlet circuit 140. Inthe latter instance, the new disconnect configuration data would then bea combination of configuration settings from the disconnectconfiguration data received from the power box 110 and new user inputreceived in step 364.

In step 366, the external device 162 transmits the new disconnectconfiguration data to the power box 110. The power box 110 receives thenew disconnect configuration data and is configured and operatedaccordingly, as described with respect to steps 308, 310, and 312.

In some instances, steps 306 and 360 are bypassed in the methods 300 and350, respectively, and the external device 162, in step 362, presentsdefault settings rather than current configuration settings of the powerbox 110. In some embodiments, method 300 of FIG. 7 is executed by thepower box 110 and method 350 of FIG. 8 is executed by the externaldevice 162 to effect configuring of the power box 110.

FIGS. 9 and 10 illustrate graphical user interfaces 400 and 401,respectively, that are implemented by the external device 162. Thegraphical user interfaces 400 and 401 are shown on a touch screendisplay 402 of the external device 162 and generated by the device userinterface 182 in conjunction with the device processor 180. Moreparticularly, the graphical user interface 400 displays a list of nearbydevices 404. Each device on the list of nearby devices 404 includes anidentifier (e.g., “Power Box 110 a”) and an icon 405. The icon 405 maybe a visual representation or image of the device. The list may begenerated as a result of step 354 described with respect to FIG. 8.Receipt of a scan command via a user input on the scan button 406 causesthe external device 162 to broadcast a polling message, to which nearbydevices respond with an advertisement message. In some instances, thedevices periodically broadcast advertisement messages without promptingby the external device 162.

Each item in the list is a device that is selectable by the user via thegraphical user interface 400. Selection of one of the nearby devicesleads to forming a communication link with the selected device (see,e.g., steps 356 and 358). Selection of a device also results ingeneration of a new screen on the touch screen display 402 forconfiguring or displaying data from the selected device (see, e.g.,steps 360 and 362). For instance, the external device 162 may receive auser selection of the power box 110 a via the graphical user interface400. In response, the external device 162 generates the graphical userinterface 401 for display on the touch screen display 402, as shown inFIG. 10.

The graphical user interface 401 includes an identification of theselected device (device ID) 408 and, initially, displays the currentconfiguration settings of the selected device. For instance, in theillustrated example, the power box 110 a includes four configurableoutlet circuits 140 a-d, each with a configurable mode and prioritylevel. The external device 162 receives the current disconnectconfiguration data from the power box 110 (step 360) and displays thecurrent mode and priority levels for each outlet circuit 140 a-d in amode display portion 410 and a priority level display portion 412 (step362). As shown, the outlet circuit 140 a is set to the prioritydisconnect mode with a priority level of 1, while the outlet circuit 140b is set to the always-on mode and the priority level is not applicable.In the illustrated graphical user interface 401, a drop down menu isprovided for each configurable mode and priority level, enabling a userto adjust the mode and priority level for each outlet circuit 140 a-d.In other embodiments, radio buttons and other selectors are provided toenable setting the mode and priority levels.

When a user changes the settings by manipulating the drop down menus(e.g., mode menu 414), the external device 162 is receiving newconfiguration data (see step 364). The new configuration data may besent automatically to the power box 110 a upon each change ortransmission of the new configuration data to the power box 110 a mayoccur after receiving a user selection of the save button 416. WhileFIG. 10 is described with respect to the power box 110 a forillustrative purposes, similar graphical user interfaces are provided inresponse to a user selection of the other power boxes 110 b and 110 c.Additionally, the graphical user interfaces 400 and 401 are merelyexemplary, as other user interfaces of the external device 162 may beused to convey and/or receive user settings that form the disconnectconfiguration data for the power boxes 110.

Furthermore, the external device 162 may obtain and display power datacaptured and output by the priority disconnect controller 150. Forinstance, the processor 166 may capture power data including powerconsumption data and quality of power data from sensor input interface168 and store the power data in the memory 164. The stored power datamay be output to the external device 162 in response to a request fromthe external device 162 based on a user input or may be outputperiodically (e.g., once an hour, day, week, or month). The powerconsumption data may indicate the amount of power consumed by loadsattached to the power box 110 either in total or per outlet circuit 140.

While the embodiments above describe a wireless communication link 184formed between the external device 162 and the power box 110 to effectconfiguration of the power box 110, in some embodiments, a wiredconnection is provided. For instance, in place of or in addition to thewireless communication module 172 and antenna 126, the power box 110includes a wired communication module and a wired communication port.Similarly, the external device 162 includes a device wired communicationmodule and a device wired communication port. A communication cable isconnected to the wired communication port and the device wiredcommunication port to form a wired communication link. The wiredcommunication link and related components may provide wiredcommunications according to various communication protocols, such as theuniversal serial bus (USB®) protocol, Firewire® protocol, RS-232protocol, and others. The methods 300 and 350 similarly apply, with somemodification for the wired, rather than wireless approach. For instance,steps 352, 354, and 356 may be bypassed as a direct connection betweenthe power box 110 and the external device 162 can serve as the selectionof the power box 110.

Thus, the invention provides, among other things, systems and methodsfor configuring a power distribution box having priority disconnects andused to distribute temporary power. Various features and advantages ofthe invention are set forth in the following claims.

What is claimed is:
 1. A method of configuring a power distribution box,the method comprising: receiving advertisement messages from a pluralityof power distribution boxes including the power distribution box inadvance of establishing a wireless communication link; displaying, on ascreen of the external setting device, a list of the plurality of powerdistribution boxes based on the received advertisement messages;receiving a user selection of a first power distribution box from thelist of the plurality of power distribution boxes; establishing, by anexternal setting device, the wireless communication link with the firstpower distribution box; providing, on the screen of the external settingdevice, a configuration screen for the first power distribution box;receiving, at the external setting device, a user input specifyingnewdisconnect configuration data, the newdisconnect configuration dataincluding a priority level and mode information for each of a pluralityof outlet circuits of the first power distribution box, wherein the modeinformation includes one selected from a group of an always-on mode inwhich a priority disconnect operation is disabled and a prioritydisconnect mode in which the priority disconnect operation is enabled;and transmitting, by the external setting device, via the wirelesscommunication link the new disconnect configuration data to the firstpower distribution box to configure the first power distribution box. 2.The method of claim 1, further comprising: receiving, from the firstpower distribution box, a notification indicating at least one selectedfrom a group consisting of a tripped breaker of the first powerdistribution box and opening of a disconnect switch associated with afirst outlet circuit of the plurality of outlet circuits.
 3. The methodof claim 1, further comprising: after establishing the wirelesscommunication link, receiving current disconnect configuration data fromthe first power distribution box, and wherein providing theconfiguration screen includes displaying current priority levels of theplurality of outlet circuits, obtained from the current disconnectconfiguration data, on the screen of the external setting device.
 4. Themethod of claim 1, further comprising: obtaining, over the wirelesscommunication link, power data captured by the first power distributionbox; and displaying the power data on the screen.
 5. A method ofconfiguring a power distribution box, the method comprising: receivingadvertisement messages at an external setting device from one or morepower distribution boxes in advance of establishing a wirelesscommunication link; displaying, on a screen of the external settingdevice, the one or more power distribution boxes based on the receivedadvertisement messages; receiving a user selection of a first powerdistribution box from the one or more power distribution boxes;establishing the wireless communication link with the first powerdistribution box based on the user selection; receiving, over thewireless communication link from the external setting device, disconnect configuration data for a plurality of outlet circuits of the firstpower distribution box, wherein the disconnect configuration dataincludes priority data and mode information for each of the plurality ofoutlet circuits; configuring the first power distribution box by settinga priority level and setting a mode for each of the plurality of outletcircuits in accordance with the priority data and mode information inthe received disconnect configuration data; receiving, at a power inputof the first power distribution box, alternating current (AC) power froman external power source; and distributing the AC power received fromthe external power source to the plurality of outlet circuits inaccordance with the priority data and the mode information in thereceived disconnect configuration data.
 6. The method of claim 5,wherein distributing the AC power received from the external powersource to the plurality of outlet circuits in accordance with thedisconnect configuration data comprises: detecting a sum current levelfor the plurality of outlet circuits; determining that the sum currentlevel exceeds a priority disconnect threshold; and in response todetermining that the sum current level exceeds the priority disconnectthreshold, selectively disconnecting a first outlet circuit of theplurality of outlet circuits from the power input based on the prioritylevel of the first outlet circuit.
 7. The method of claim 5, furthercomprising broadcasting, by the one or more power distribution boxes,the advertisement messages to the external setting device to identifythe one or more power distribution boxes in advance of establishing thewireless communication link.
 8. The method of claim 5, furthercomprising after establishing the wireless communication link and beforereceiving the disconnect configuration data, transmitting, over thewireless communication link, current disconnect configuration data ofthe first power distribution box, wherein the current disconnectconfiguration data includes an initial priority level for each of theplurality of outlet circuits.
 9. The method of claim 5, wherein the modeof each of the plurality of outlet circuits is one selected from thegroup of an always-on mode in which a priority disconnect operation isdisabled and a priority disconnect mode in which the priority disconnectoperation is enabled.
 10. The method of claim 5, further comprisingtransmitting, by the first power distribution box, a notification to theexternal setting device indicating at least one selected from a groupconsisting of a tripped breaker of the first power distribution box andopening of a disconnect switch associated with a first outlet circuit ofthe plurality of outlet circuits.
 11. The method of claim 5, furthercomprising: capturing power data from a current sensor; andtransmitting, by the first power distribution box, the power data overthe wireless communication link.
 12. The method of claim 5, furthercomprising: detecting a sum current level for the plurality of outletcircuits; and generating, by an indicator on the first powerdistribution box, an indication that the sum current level isapproaching a priority disconnect threshold before the sum current levelexceeds the priority disconnect threshold.
 13. The method of claim 5,further comprising: detecting a first current level for a first outletcircuit of the plurality of outlet circuits; and generating, by a lightindicator on the first power distribution box, an indication that thefirst current level is approaching an individual current thresholdbefore the first current level exceeds the individual circuit currentthreshold.
 14. A system comprising: an external device configured to:receive advertisement messages from one or more power distribution boxesin advance of establishing a wireless communication link; display, on ascreen of the external setting device, the one or more power boxes basedon the received advertisement message; receive a user selection of afirst power distribution box from the one or more power distributionboxes; and establish the wireless communication link with the firstpower distribution box based on the user selection, the first powerdistribution box comprising: a housing portion; a base portion elevatingthe housing portion above a surface on which the first powerdistribution box is placed; a power source input operable to receivepower from an external power source; a plurality of outlet circuitselectrically coupled to the power source input; an antenna; a powerdisconnect controller coupled to the antenna and configured to, receive,over the established wireless communication link, disconnectconfiguration data, and assign priority levels and modes to theplurality of outlet circuits as specified by the disconnectconfiguration data received from the external device.
 15. The system ofclaim 14, wherein the first power distribution box further comprises: aplurality of disconnect switches, each coupled to one of the pluralityof outlet circuits, wherein the power disconnect controller is coupledto each of the plurality of disconnect switches and configured toindividually control the plurality of disconnect switches.
 16. Thesystem of claim 14, wherein the first power distribution box furthercomprises: a wireless communication circuit coupled to the antenna andconfigured to establish the wireless communication link with theexternal device and to receive, over the wireless communication link,the disconnect configuration data; a memory storing the disconnectconfiguration data received from the external setting device; one ormore current sensor inputs configured to receive current data fromcurrent sensors associated with the plurality of outlet circuits; and aprocessor configured to control a plurality of disconnect switches, eachcoupled to one of the plurality of outlet circuits, based on the currentdata and the disconnect configuration data.
 17. The system of claim 16,wherein the power disconnect controller further comprises a controloutput unit coupled to the processor and to the plurality of disconnectswitches, the control output unit providing an interface between theprocessor and the plurality of disconnect switches.
 18. The system ofclaim 14, wherein the disconnect configuration data further specifies amode of each of the plurality of outlet circuits, and wherein the modeis one selected from a group of an always-on mode in which a prioritydisconnect operation is disabled and a priority disconnect mode in whichthe priority disconnect operation is enabled.
 19. The system of claim14, wherein the power disconnect controller is further configured totransmit, to the external device over the wireless communication link,at least one selected from a group consisting of: the disconnectconfiguration data; a first notification of a tripped breaker of thefirst power distribution box; and a second notification of opening of adisconnect switch associated with a first outlet circuit of theplurality of outlet circuits.
 20. The system of claim 14, wherein thefirst power distribution box further comprises an indicator coupled tothe power disconnect controller, wherein the power disconnect controllercontrols the indicator to indicate at least one selected from a groupof: a sum current level of the plurality of outlet circuits isapproaching a priority disconnect threshold before the sum current levelexceeds the priority disconnect threshold; and a first current level ofa first outlet circuit of the plurality of outlet circuits isapproaching an individual circuit current threshold before the firstcurrent level exceeds the individual circuit current threshold.